DRYER MACHINE AIR RECYCLING MODULE

Description

TECHNICAL FIELD

The described embodiments relate generally to improving dryer machine efficiency, and more particularly to use of an air recycler module to improve dryer machine efficiency.

BACKGROUND INFORMATION

Dryer machines, commonly used in households and industrial settings, are appliances designed for drying clothes and other textiles quickly and efficiently. They typically operate by blowing hot air into the drying chamber, where the warm air circulates around the wet clothes, evaporating moisture and leaving them dry. Power consumption of dryer machines can vary depending on factors like the machine's size, heating element efficiency, and the drying time required. Traditional electric dryers tend to have higher power consumption compared to gas dryers, as they use electric heating elements. Over recent years, there has been a growing concern about the energy efficiency of dryer machines, as they can consume a significant amount of electricity during operation. To address these efficiency concerns, manufacturers have developed energy-efficient models that incorporate features like optimized drying time, heat pump technology for lower energy consumption, and improved insulation to retain heat within the drum. Consumers are encouraged to choose energy-efficient dryers and use them wisely to reduce power consumption and environmental impact. Additionally, line drying or air drying remains an eco-friendly alternative for reducing energy consumption associated with drying clothes.

SUMMARY

In a first novel aspect, an air recycling module includes a housing, wherein the housing further comprises: a first air input opening, a first air output opening, and a second air output opening. The air recycling module also includes a first damper configured to control a flow of air passing through the first air output opening, a first damper motor configured to control the position of the first damper, a damper controller configured to operate the first damper motor, a power port configured to connect to a power source, a first sensor configured to measure a first characteristic of a flow of air passing through the first air input opening, and a second sensor configured to measure a second characteristic of the flow of air passing through the first air input opening. The first sensor is configured to generate a first sensor signal and the second sensor is configured to generate a second sensor signal. The damper controller is configured to receive and configured to process the first sensor signal and the second sensor signal. The damper controller is further configured to control the operation of the damper by controlling the damper motor. The position of the damper is based, at least in part, on the first sensor signal and the second sensor signal.

In a second novel aspect, a method of air recycling, includes (a) receiving air output by a dryer machine, (b) measuring a one or more characteristics of the dryer machine air output, (c) determining if the one or more dryer machine air output characteristics meet a on or more requirements, (d) causing the dryer machine air output to be routed back to a dryer machine air inlet if it is determined in (c) that the one or more dryer machine air output characteristics meet the one or more requirements; and (e) causing the dryer machine air output to not be routed back to a dryer machine air inlet if it is determined in (c) that the one or more dryer machine air output characteristics do not meet the one or more requirements.

Further details and embodiments and techniques are described in the detailed description below. This summary does not purport to define the invention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, where like numerals indicate like components, illustrate embodiments of the invention.

FIG. 1 is a perspective view diagram of a dryer machine illustrating the various components contained therein.

FIG. 2 is a side view diagram of dryer machine illustrating exhaust venting.

FIG. 3 is a rear perspective view of a drying machine illustrating air inlets, power cable, and exhaust outlet.

FIG. 4 is a perspective view diagram of an improved dryer machine utilizing an air recycling module.

FIG. 5 is a diagram of an air recycling module including a single damper.

FIG. 6 is a diagram of an air recycling module including a single damper illustrating air flow in a first configuration.

FIG. 7 is diagram of an air recycling module including a single damper illustrating air flow in a second configuration.

FIG. 8 is a diagram of an air recycling module including two dampers illustrating air flow in a first configuration.

FIG. 9 is a diagram of an air recycling module including two dampers illustrating air flow in a first configuration.

FIG. 10 is a diagram of an air recycling module including two dampers illustrating air flow in a second configuration.

FIG. 11 is a flowchart of an air recycling module operating in combination with a dryer machine.

DETAILED DESCRIPTION

Reference will now be made in detail to background examples and some embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the description and claims below, relational terms such as “top”, “down”, “upper”, “lower”, “top”, “bottom”, “left” and “right” may be used to describe relative orientations between different parts of a structure being described, and it is to be understood that the overall structure being described can actually be oriented in any way in three-dimensional space.

FIG. 1 is a perspective view diagram of a dryer machine illustrating the various components contained therein. The dryer machine includes a door, a door catch 1, a door gasket 2, a drum, drum support rollers 3, idler pulley and spring 4, a motor 5, a blower 6, a drum belt 7, an air inlet 8, a power cord that is configured to connect to a power source 9, a exhaust duct 10 configured to connect to an exhaust outlet, controls and monitors 11, a lint trap 12, a thermostat 13, and a heating duct and element 14. In operation the dryer components work in concert to generate hot, dry air that is circulated throughout the drum containing the wet articles to be dried. The dryer expels the air after it has absorbed the moisture from the wet articles in the drum. The expelled air is then directed to a space outside of the drum.

In this manner the dryer functions by continually cycling in ambient air into the dryer via the air inlet, heating the ambient air, directing the heated air through the wet articles, and then directing the moist air be output via an exhaust outlet. This procedure is continued until the wet articles in the drum of the dryer machine are dry.

One example where the output air flow from the drying machine is passed through an exhaust outlet and an exhaust vent 15 to an outside space is illustrated in FIG. 2. In this example illustrated in FIG. 2, the exhaust vent (or ducting) passes through a wall to separate the air intake space from the exhaust output space.

A dryer machine may have one or more air inlets located on the rear panel of the dryer machine 16 as illustrated in FIG. 3. An exhaust outlet 17 may also be located on the rear panel of the dryer machine along with a power cable 18 configured to connect to a local power source.

In a new and improved embodiment of the present invention, an air recycling module 30 can be utilized to improve the functionality and efficiency of the dryer machine. The dryer machine itself operates in a normal fashion with out any adjustments or modifications. The air recycling module 30 is inserted into the exhaust air path and intelligently routes the exhausted air from the dryer machine depending on one or more measurements. If the air recycling module 30 determines that the exhaust air from the dryer machine should be expelled, then the air recycling module 30 routes the exhaust air from the dryer machine out through exhaust vent 32. If the air recycling module 30 determines that the exhaust air from the dryer machine should be directed back to the dryer machine inlet 41, then the air recycling module 30 routes the exhaust air from the dryer machine out through feedback ducting 46. The output of feedback ducting 46 is attached to, or opens at a location near, the air inlet 41 of the dryer machine. The air recycling module 30 is also configured to couple to a power source 33 via a power cable.

The air recycling module 30 is shown in greater detail in FIG. 4. The exemplary embodiment illustrated in FIG. 4 includes a single damper 41, the position of which is controlled by motor 42. Motor 42 is controlled by damper controller 43.

It is noted herein, damper controller 43 may be implemented in a variety of ways. In a first embodiment, the damper controller 43 may be implemented utilizing a processing circuit configured to execute instructions stored in a local memory, and to read one or more input signals on input/output pins. In a second embodiment, the damper controller 43 may be implemented by utilizing combinatory logic that is triggered by one or more inputs and a clock signal. In a third embodiment, the damper controller 43 may be implemented by a combination of comparator circuits that output a desired voltage or current based upon one or more input signals. With these various embodiments in mind, the high-level functionality of the damper controller 43 is disclosed.

The damper controller 43 is configured to receive a measurement signal and in response to the measurement signal, the damper controller 43 is configured to adjust the damper motor 42. Adjustment of the damper motor 42 in turn causes the position of damper 41 to be adjusted. FIG. 4 is a perspective view diagram of an improved dryer machine utilizing an air recycling module.

In the embodiment illustrated in FIG. 5 the air recycling module includes two sensors, both of which communicate a measurement signal to the damper controller 43. In one example, the measurement signals are communicated electrically via an electrical conduit connecting the sensor with the damper controller 43. In another example, the measurement signals are communicated wirelessly via an electromagnetic signal traveling from the sensor to the damper controller 43.

In operation, dryer machine exhaust air travels through the exhaust ducting 46 into the air recycling module. The temperature of the exhaust air is measured by temperature sensor 44. The humidity of the exhaust air is measured by the humidity sensor 45. In response to exposure to the exhaust air, the temperature sensor communicates a signal associated with the exhaust air temperature to the damper controller 43. In response to the exposure to the exhaust air, the humidity sensor communicates a signal associated with the exhaust air humidity to the damper controller 43. The damper controller 43 then determines how the exhaust air is to be routed based at least in part on the signal received from the temperature sensor and the signal received from the humidity sensor.

In one example, the damper controller is configured to only route the exhaust air to the recycled air ducting 47 when the temperature sensor signal indicates that the temperature of the exhaust air is above a temperature threshold value and when the humidity sensor signal indicates that the humidity of the exhaust air is below a humidity threshold. The temperature threshold value and the humidity threshold value may be adjustable to optimize drying performance and energy efficiency. In one embodiment, the temperature threshold is ninety-five (95) degrees Fahrenheit and the humidity threshold is sixty-five (65) percent humidity. This scenario is illustrated in FIG. 7. The damper controller 43 communicates a control signal to damper motor 42 thereby causing damper 41 to rotate to an open position. The opening of damper 41 results in the main path of air flow 49 to travel from exhaust ducting 46 through the air recycling module and out via recycled air ducting 47 to the dryer machine air inlet.

When the temperature sensor signal indicates that the temperature of the exhaust air is below the temperature threshold value or when the humidity sensor signal indicates that the humidity of the exhaust air is above a humidity threshold, the damper controller 43 causes the exhaust air 49 to be routed to output ducting 48. This scenario is illustrated in FIG. 6. The damper controller 43 communicates a control signal to damper motor 42 thereby causing damper 41 to rotate to a closed position. The closure of damper 41 results in the main path of air flow 49 to travel from exhaust ducting 46 through the air recycling module and out via output ducting 48.

Another embodiment of the present invention is illustrated in FIG. 8. The air recycling module of FIG. 8 includes a first damper 51 controlling air flow through recycled air ducting 57 and a second damper 59 controlling air flow through output ducting 58. The operation of the damper controller and the damper 51 controlling the air flow through recycled air ducting 57 is the same as described above regarding FIGS. 5-7, however, the present embodiment adds damper 59 to further control the air flow through output ducting 58. In operation, as illustrated in FIG. 9, when damper controller 53 determines that damper 51 is to be closed so to block air flow through recycled air ducting 57, the damper controller 53 sends a control signal to damper motor 60 causing damper 59 to be opened. Alternatively, as illustrated in FIG. 10, when damper controller 53 determines that damper 51 is to be opened so to allow air flow through recycled air ducting 57, the damper controller 53 sends a control signal to damper motor 60 causing damper 59 to be closed. In this fashion, the use of two dampers allows exact control of how much air passes through output ducting 58 and recycled air ducting 57 at any time.

FIG. 11 is a flowchart 200 of an air recycling module operating in combination with a dryer machine. In step 201, air output by a dryer machine is received. In step 202, one or more characteristics of the air output by the dryer machine is measured. The characteristics may be temperature, humidity, or any other useful characteristic. In step 203, it is determined if the dryer machine air output characteristics meet one or more requirements. In step 204, if the dryer machine air output characteristic(s) meet the requirement(s), then the dryer machine air output is caused to be routed back to an air inlet in the dryer machine. In step 205, if the dryer machine air output characteristic(s) do not meet the requirement(s), then do not cause the dryer machine air output to be routed back to an air inlet of the dryer machine.

Various Types of Humidity Sensors May be Used

Various type of humidity sensors may be used to implement the current invention. The following list includes some of the various types of humidity sensors that could be used.

Capacitive Humidity Sensors: These sensors measure humidity by detecting changes in the electrical capacitance between two electrodes as the humidity level changes. They are commonly used and offer good accuracy.

Resistive Humidity Sensors (Hygroresistors): Resistive humidity sensors use a hygroscopic material that changes resistance with varying humidity levels. The resistance is measured to determine humidity.

Thermal Conductivity Humidity Sensors: Thermal conductivity humidity sensors measure humidity by monitoring the change in the thermal conductivity of air as it varies with moisture content. They are suitable for high-temperature applications.

Gravimetric Humidity Sensors: Gravimetric humidity sensors measure humidity by weighing a moisture-absorbing material and calculating the humidity based on the weight change. They offer high accuracy but are relatively slow.

Dew Point Sensors: Dew point sensors determine the dew point temperature, at which air becomes saturated and moisture begins to condense. They are used in applications where condensation needs to be prevented.

Spectroscopic Humidity Sensors: Spectroscopic sensors use the absorption or transmission of specific wavelengths of light to measure humidity. They can provide accurate measurements but are often more complex and costly.

Grain Moisture Sensors: These sensors are specifically designed to measure the moisture content in grains, seeds, and agricultural products. They help ensure proper storage conditions.

Acoustic Humidity Sensors: Acoustic humidity sensors utilize changes in the speed of sound in air as humidity levels change. They are used in applications where rapid response times are essential.

Thin-Film Humidity Sensors: Thin-film sensors have a thin layer of humidity-sensitive material deposited on a substrate. Changes in the film's properties are used to measure humidity.

Optical Humidity Sensors: Optical humidity sensors use changes in the refractive index of materials with varying humidity to determine moisture levels. They can offer high precision.

Piezoelectric Humidity Sensors: Piezoelectric humidity sensors rely on the deformation of a piezoelectric crystal due to humidity-induced stress. The resulting electrical signal is proportional to humidity.

Radio Frequency (RF) Humidity Sensors: RF humidity sensors measure the dielectric properties of materials influenced by humidity changes at radio frequencies. They are suitable for wireless sensing applications.

Micro-Electro-Mechanical Systems (MEMS) Humidity Sensors: MEMS humidity sensors are miniaturized devices that use microstructures to measure humidity. They are commonly integrated into electronic systems.

Conductivity-Based Humidity Sensors: These sensors measure humidity by detecting changes in electrical conductivity in a hygroscopic material as it absorbs moisture.

Color-Based Humidity Indicators: Color-changing humidity indicators consist of materials that change color as humidity levels change. They are often used for visual humidity monitoring.

Wireless Humidity Sensors: Wireless humidity sensors can transmit humidity data wirelessly to a central monitoring system, making them suitable for remote and distributed monitoring applications.

Various Types of Temperature Sensors May Be Used

Various type of temperature sensors may be used to implement the current invention. The following list includes some of the various types of temperature sensors that could be used.

Thermocouples: Thermocouples are temperature sensors that use the Seebeck effect, generating a voltage when two dissimilar metal wires are joined. The voltage is proportional to the temperature difference between the junction and a reference point.

Resistance Temperature Detectors (RTDs): RTDs are temperature sensors that rely on the change in electrical resistance of a pure metal (usually platinum) with temperature. They offer high accuracy and stability.

Thermistors (NTC and PTC): Thermistors are temperature-sensitive resistors. NTC (Negative Temperature Coefficient) thermistors have resistance that decreases with increasing temperature, while PTC (Positive Temperature Coefficient) thermistors have resistance that increases with temperature.

Infrared (IR) Sensors: Infrared sensors measure temperature by detecting the thermal radiation emitted by an object. They are non-contact sensors commonly used in industrial and medical applications.

Bimetallic Temperature Sensors: Bimetallic sensors consist of two different metals bonded together. They bend or curve when heated due to differential expansion, and this mechanical deformation is used to measure temperature.

Semiconductor Temperature Sensors: Semiconductor temperature sensors use the temperature-dependent electrical characteristics of semiconductor materials (e.g., silicon) to measure temperature. They are often integrated into electronic devices.

Gas Thermometers: Gas thermometers use the expansion or contraction of a gas (typically helium or hydrogen) with temperature changes to measure temperature accurately in various applications.

Liquid-in-Glass Thermometers: These traditional thermometers contain a liquid (e.g., mercury or alcohol) inside a glass tube. The liquid expands or contracts with temperature, causing it to rise or fall within a calibrated scale.

Fiber Optic Temperature Sensors: Fiber optic sensors measure temperature by monitoring changes in the optical properties of optical fibers as temperature varies. They are suitable for applications where electrical sensors are not ideal.

Surface Temperature Sensors: Surface temperature sensors are designed to make direct contact with a surface to measure its temperature accurately. They include contact probes and non-contact infrared sensors.

Gas Expansion Thermometers: Gas expansion thermometers use the change in the volume of a gas (usually nitrogen) enclosed in a bulb to measure temperature. The pressure change corresponds to temperature.

Vapor Pressure Thermometers: Vapor pressure thermometers rely on the variation in vapor pressure of a volatile liquid with temperature. The pressure is measured to determine the temperature.

Benefits of the Invention

An Air Recycling Module (“ARM”) is an innovative technology that enhances the efficiency and sustainability of dryer machines by intelligently routing the dryer machine's air exhaust back to the dryer machine's air inlet. This process allows for the reuse of the hot and dry air expelled from the dryer, offering several significant benefits:

Energy Efficiency: One of the primary benefits of an ARM is its contribution to energy efficiency. By recirculating the hot and dry air within the dryer system, the need for constantly heating incoming air is reduced. This results in substantial energy savings as the dryer consumes less electricity or gas to achieve the desired drying temperatures. As a result, homeowners and businesses can lower their utility bills and reduce their environmental footprint.

Faster Drying Times: Reusing the preheated air from the dryer's exhaust means that the air entering the drying chamber is already at an elevated temperature. This results in quicker and more efficient drying cycles, reducing the overall drying time required for laundry or other materials. Faster drying times can lead to increased productivity in commercial or industrial settings.

Extended Appliance Lifespan: The reduced strain on the heating elements and components of the dryer machine, thanks to the recirculated air, can contribute to a longer appliance lifespan. This can lead to cost savings for homeowners and businesses by minimizing the need for repairs or replacements.

Environmental Benefits: ARM technology aligns with sustainability goals by reducing energy consumption and greenhouse gas emissions associated with dryer operation. By making more efficient use of energy resources, it helps decrease the carbon footprint of laundry facilities and promotes a more environmentally friendly approach to drying clothes.

Consistent Drying Results: The reuse of hot and dry air ensures a consistent drying environment within the dryer chamber. This can lead to more predictable and uniform drying results, reducing the risk of over-drying or under-drying garments and fabrics.

Cost Savings: Over time, the energy savings achieved by using an ARM can translate into substantial cost savings for both residential and commercial users. Lower energy bills and reduced maintenance expenses contribute to the return on investment for this technology.

In conclusion, an Air Recycling Module intelligently routing dryer machine air exhaust back to the dryer machine air inlet is a game-changer in terms of improving the efficiency, sustainability, and overall performance of dryer machines. It offers numerous benefits, including energy savings, faster drying times, extended appliance lifespan, environmental advantages, improved comfort, consistent drying results, and cost savings. As sustainability and energy efficiency become increasingly important, ARM technology represents a significant step towards reducing the environmental impact of drying processes while providing practical advantages for users.

Although certain specific embodiments are described above for instructional purposes, the teachings of this patent document have general applicability and are not limited to the specific embodiments described above. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.